Systems and methods for rotating and coating an implantable device

ABSTRACT

A method for applying a coating to an implantable device is disclosed. The method includes positioning an implantable device relative to an ultrasonic material delivery apparatus. The implantable device is rotated at a relative speed. The relative speed may be more than 120 revolutions per minute. An application material is applied to the implantable device using the ultrasonic material delivery apparatus. The relative speed may be sufficient to reduce the size of at least a portion of droplets of the application material. A system for rotating an implantable device is disclosed. The system includes an implantable device and a rotation system configured to rotate the implantable device. A longitudinal axis of the implantable device and a longitudinal axis of a rotation member of the rotation system may be offset a desired dimension. An inside diameter of the implantable device may be larger than an outside diameter of a rotation member.

FIELD OF THE INVENTION

The present invention relates generally to medical devices, and moreparticular to methods for applying an application material to animplantable device and systems and methods for rotating and coating animplantable device.

BACKGROUND OF THE INVENTION

Percutaneous transluminal coronary angioplasty (PTCA) is a procedure fortreating heart disease. This procedure generally entails introducing aballoon catheter assembly into the cardiovascular system of a patientvia the brachial or femoral artery and advancing the balloon catheterassembly through the coronary vasculature until the balloon ispositioned across an occlusive lesion. Once in position across thelesion, the balloon is inflated to a predetermined size to radiallycompress against the atherosclerotic plaque of the lesion to remodel thevessel wall. Subsequently, the balloon is deflated to allow the ballooncatheter assembly to be withdrawn from the vasculature.

While PTCA is widely used, it suffers generally from two uniqueproblems. First, the blood vessel may suffer acute occlusion immediatelyafter or within the initial hours after the dilation procedure. Suchocclusion is referred to as “abrupt closure.” Abrupt closure occurs inapproximately five percent of cases in which PTCA is employed. Theprimary mechanisms of abrupt closures are believed to be elastic recoil,arterial dissection, vasospasm, and/or thrombosis. The second problemassociated with this procedure is the re-narrowing of an artery after aninitially successful angioplasty.

This re-narrowing is referred to as “restenosis,” which typically occurswithin the first six months after angioplasty. Restenosis is believed tobe due to, among other things, the proliferation and migration ofcellular components from the arterial wall, as well as through geometricchanges in the arterial wall referred to as “remodeling.”

To reduce occlusion of the artery, and the development of thrombosisand/or restenosis, an expandable interventional device or prosthesis,one example of which includes a stent, may be implanted in the lumen tomaintain the vascular patency. Additionally, to better effectuate thetreatment of such vascular disease, it may be preferable to load anintraluminal device or prosthesis with one or more beneficial agents,such as antiproliferatives, for delivery to a lumen. One commonlyapplied technique for the local delivery of a drug is the use of apolymeric carrier coated onto the surface of a stent. Such conventionalmethods and products generally have been considered satisfactory fortheir intended purpose.

However, implantable devices, such as stents, may be difficult to coatwithout webbing, cobwebs, or other defects due to their generallyintricate geometry. They may also be difficult to uniformly coat (i.e.on the ablumenal, luminal, and sidewall surfaces). Because of thesechallenges, many commercialized drug eluting stents are being coated bya spray process. However, spray coating may suffer generally from thefollowing: reduced coating speed, reproducibility, and/or coatingefficiency (i.e. the amount of material sprayed actually coating thedevice).

Accordingly, it may be desirable to provide systems and methods forrotating and coating an implantable device.

BRIEF SUMMARY

An embodiment of a method for applying a coating to an implantabledevice is described. The method includes positioning an implantabledevice relative to a material delivery apparatus. The implantable deviceis rotated at a relative speed of more that about 120 revolutions perminute. A spray pattern of an application material is produced using thematerial delivery apparatus.

In some embodiments, the relative speed is between about 200 revolutionsper minute and about 3000 revolutions per minute. In furtherembodiments, a distance between the implantable device and the materialdelivery apparatus is between about 1 mm and about 50 mm. In stillfurther embodiments, the implantable device is a stent.

Another embodiment of a method for applying a coating to an implantabledevice is described. The method includes positioning an implantabledevice relative to a material delivery apparatus. A spray pattern of anapplication material is produced using the material delivery apparatus.The implantable device is rotated at a relative speed sufficient toreduce the size of a portion of droplets of the spray pattern.

In some embodiments, the relative speed is generally sufficient todeflect a portion of the droplets of the spray pattern from a firstportion of the implantable device toward a second portion of theimplantable device. The relative speed, in further embodiments, isgenerally sufficient to coat at least a portion of an internal surfacewith application material without increasing a flow rate of theapplication material. In still further embodiments, the relative speedis generally sufficient to reduce buildup of the application material.

A system for rotating an implantable device is described. The systemincludes an implantable device having a first longitudinal axis and aninside diameter. The system includes a rotation system configured torotate the implantable device. The rotation system includes a rotationmember having a second longitudinal axis and an outside diameter. Therotation member is rotationally associated with a rotation mechanism.When the first longitudinal axis and the second longitudinal axis aregenerally parallel, the first longitudinal axis and the secondlongitudinal axis are offset a desired dimension.

In some embodiments, the desired dimension is between about 0.02 mm andabout 1.97 mm. The desired dimension, in further embodiments, is betweenabout 0.3 mm and about 0.5 mm. In still further embodiments, the desireddimension is between about 5% and about 5000% of the outside diameter ofthe rotation member.

Another embodiment of a system for rotating an implantable device isdescribed. The system includes an implantable device having an insidediameter. The system includes a rotation system configured to rotate theimplantable device. The rotation system includes a rotation memberhaving an outside diameter. The rotation member is rotationallyassociated with a rotation mechanism. The outside diameter of therotation member is smaller than the inside diameter of the implantabledevice.

In some embodiments, the inside diameter of the implantable device isbetween about 0.05 mm and about 2.0 mm. The outside diameter of therotation member, in further embodiments, is between about 0.03 mm andabout 1.7 mm. In still further embodiments, the outside diameter of therotation member is between about 0.5 mm and about 0.7 mm and the insidediameter of the implantable device is about 1.0 mm.

The outside diameter of the rotation member, in some embodiments, ismore than about 5% and less than about 100% of the inside diameter ofthe implantable device. In further embodiments, the outside diameter ofthe rotation member is more than about 50% and less than about 70% ofthe inside diameter of the implantable device.

A further embodiment of a method for rotating an implantable device isdescribed. The method including positioning a generally annularimplantable device having an inner surface relative to a rotation memberhaving an outer surface such that less than the entire inner surface ofthe implantable device and less than the entire outer surface of therotation member are in general contact with each other. A rotationalforce is applied to the rotation member, such that the rotation memberbegins to rotate at a specified rotation speed causing at least aportion of the outer surface of the rotation member to apply africtional force to at least a portion of the inner surface of theimplantable device.

In some embodiments, the frictional force between the rotation memberand the implantable device causes the implantable device to rotate at aspeed corresponding to the specified rotation speed of the rotationmember. The frictional force between at least a portion of the outersurface of the rotation member and at least a portion of the innersurface of the implantable device, in further embodiments, is due to thebuild up of kinetic energy between at least a portion of the outersurface of the rotation member and at least a portion of the innersurface of the implantable device when the rotation member is rotatedrelative to the implantable device. In still further embodiments, thefrictional force between at least a portion of the outer surface of therotation member and at least a portion of the inner surface of theimplantable device is due to the build up of kinetic energy between atleast a portion of the outer surface of the rotation member, at least aportion of the inner surface of the implantable device, and a fluidbetween at least a portion of the outer surface of the rotation memberand at least a portion of the inner surface of the implantable devicewhen the rotation member is rotated relative to the implantable device.

It is to be understood that both the foregoing general description andthe following detailed description are exemplary and are intended toprovide further explanation of the invention claimed.

The accompanying Figures, which are incorporated in and constitute partof this specification, are included to illustrate and provide a furtherunderstanding of the method and system of the invention. Together withthe description, the Figures serve to explain the principles of theinvention.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to describe the manner in which the above-recited and otheradvantages and features of the invention can be obtained, a moreparticular description of the invention briefly described above will berendered by reference to specific embodiments thereof which areillustrated in the appended drawings. Understanding that these drawingsdepict only typical embodiments of the invention and are not thereforeto be considered to be limiting of its scope, the invention will bedescribed and explained with additional specificity and detail throughthe use of the accompanying drawings.

FIG. 1 illustrates a block diagram of an embodiment of a system forrotating and coating an implantable device, in accordance with thepresent invention.

FIG. 2 illustrates a schematic representation of another embodiment of asystem for rotating and coating an implantable device, in accordancewith the present invention.

FIG. 3 illustrates an embodiment of an implantable device, in accordancewith the present invention.

FIG. 4 illustrates a cross-sectional view of an embodiment of animplantable device and a rotation member, in accordance with the presentinvention.

FIG. 5 illustrates a cutaway perspective view of an embodiment of animplantable device having struts and various droplets of an applicationmaterial, in accordance with the present invention.

FIG. 6 illustrates an embodiment of a method for rotating and coating animplantable device, in accordance with the present invention.

FIG. 7 illustrates a block diagram of a still further embodiment of asystem for rotating and coating an implantable device, in accordancewith the present invention.

It should be noted that the figures are not drawn to scale and thatelements of similar structures or functions are generally represented bylike reference numerals for illustrative purposes throughout thefigures. It also should be noted that the figures are only intended tofacilitate the description of embodiments of the present invention.

DETAILED DESCRIPTION

Methods and apparatus for rotating and applying a coating to animplantable device are described. Some embodiments of the methods mayinclude rotating an implantable device at a relative speed. The relativespeed may include various speeds that may be sufficient to facilitate areduction in the size of and/or an increase in the spatial resolution ofa portion of droplets produced by a material delivery apparatus. Anincrease in spatial resolution may include an increase in the number ofdroplets within a volume. Some embodiments of the apparatus may includea rotation system that may rotate an implantable device. The implantabledevice may be held by a rotation member that may have a smaller diameterthan that of the implantable device.

These results, whether individually or collectively, can be achieved,according to one embodiment of the present invention, by employingmethods, systems, and/or apparatus as shown in the figures and describedin detail below.

Turning now to the drawings, FIG. 1 illustrates a block diagram of anembodiment of a system 100 for rotating and coating an implantabledevice 180, in accordance with the present invention. The system 100includes a material delivery apparatus 102 that may apply an applicationmaterial 170 to an implantable device 180. In some embodiments, thematerial delivery apparatus 102 may include an ultrasonic materialdelivery apparatus. In further embodiments, the material deliveryapparatus 102 may include an ink jet print head. The applicationmaterial 170 may be applied at a desired spray pressure. In the presentembodiment, the spray pressure may be between about 2 psi and about 30psi. The spray pressure may be varied and/or may be fixed. Inembodiments where the material delivery apparatus 102 use an ink jetprint head, the spray pressure may be less than 2 psi. For example, thespray pressure may even be approximately zero. The spray pressure mayaffect the size, velocity, and/or drying rate of at least a portion ofthe droplets.

The material delivery apparatus 102 may be positioned in a desiredlocation and/or in a desired orientation. For example, the implantabledevice 180 may be positioned between about 1 mm and about 50 mm from thematerial delivery apparatus 102 and/or oriented perpendicular to theapplication 170 material being applied. In some embodiments, theimplantable device 180 may be positioned less than about 1 mm from thematerial delivery apparatus 102. For example, a material deliveryapparatus 102 that uses an ink jet print head may be positioned lessthan about 1 mm from the implantable device 180.

The system 100 may include a rotation system 105. The rotation systemmay be configured to rotate the implantable device 180. Applicationmaterial 170 may be applied to the implantable device 180 duringrotation. The application material 170 may include beneficial agents,imaging materials, solvents, and/or other application materials.

Beneficial agents may include analgesics, antipyretics, antiasthamatics,antibiotics, antidepressants, antidiabetics, antifungal agents,antihypertensive agents, anti-inflammatories including non-steroidal andsteroidal, antineoplastics, antianxiety agents, immunosuppressiveagents, antimigraine agents, sedatives, hypnotics, antianginal agents,antipsychotic agents, antimanic agents, antiarrhythmics, antiarthriticagents, antigout agents, anticoagulants, thrombolytic agents,antifibrinolytic agents, hemorheologic agents, antiplatelet agents,anticonvulsants, antiparkinson agents, antihistamines, anti-restenosisagents, antipruritics, agents useful for calcium regulation,antibacterial agents, antiviral agents, antimicrobials, anti-infectives,bronchodilators, steroidal compounds and hormones, or combinationsthereof. The active agent may include at least one of rapamycin,rapamycin analog, sirolimus, everolimus, zotarolimus,40-epi-(N1-tetrazolyl)-rap amycin,40-O-[2-(2-hydroxy)ethoxy]ethyl-rapamycin, Biolimus A9 (BiosensorsInternational, Singapore), deforolimus, AP23572 (Ariad Pharmaceuticals),dexamethasone, dexamethasone acetate, dexmethasone phosphate,momentasone, cortisone, cortisone acetate, hydrocortisone, prednisone,prednisone acetate, betamethasone, betamethasone acetate, prednisone,hydrocortisone, estradiol, acetaminophen, ibuprofen, naproxen, sulidac,heparin, taxol, paclitaxel, and/or combinations thereof.

Imaging materials may include materials, such as radiopaque materials.Examples of radiopaque materials may include high-density materials suchas gold, platinum, platinum/iridium, tantalum, tungsten, gadoliniumsalts, gadolinium complexes, bismuth compounds, barium compounds, and/orother radiopaque materials. As used herein, the term radiopaque mayinclude partial radiopacity as well as total radiopacity.

Solvents may include methanol, ethanol isopropanol, n-propanol,isobutanol, sec-butanol, n-butanol, benzyl alcohol, alcohols, diethylether, tetrahydrofuran, 1,4-dioxane, ethers, butyl acetate, isopropylacetate, ethyl acetate, methyl acetate, esters, acetone, 4-butanone,cyclopentanone, cyclohexanone, ketones, 1-methoxy-2-propanol, diacetonealcohol, methylene chloride, chloroform, carbon tetrachloride,1,1,1-trichloroethane, trichloroethylene, chlorobenzene, freons,pentane, hexane, cyclohexane, n-heptane, n-octane, benzene, toluene,o-xylene, p-xylene, m-xylene, dimethylenformamide, formamide,dimethylacetamide, dimethylsulfoxide, sulfolane, hexamethylphosphorustriamide, n-methylpyrrolidone, 1,1,1-trifluoroethanol,hexafluoroisopropanol, water, and/or other solvents.

Other application materials may include polymeric materials comprised ofphosphorylcholines, phosphorylcholine linked macromolecules,polyolefins, poly(meth)acrylates, polyurethanes, polyesters,polyanhydrides, polyphosphazenes, polyacrylates, acrylic polymers,poly(lactide-coglycolides) (PLGA), polylactic acids (PLA),poly(hydroxybutyrates), poly(hydroxybutyrate-co-valerates),polydioxanones (PDO), polyorthoesters, polyglycolic acids (PGA),polycaprolactones (PCL), poly(glycolic acid-co-trimethylene carbonates),polyphosphoesters, polyphosphoester urethanes, poly(amino acids),cyanoacrylates, poly(trimethylene carbonate), poly(iminocarbonate),polyalkylene oxalates, polyiminocarbonates, aliphatic polycarbonates,fibrins, fibrinogens, celluloses, starchs, collagens, polycarbonateurethanes, polyisoprenes, polyisobutylenes, polybutadienes,polyethylenes, plasticized polyethylene terephthalates, polyethyleneterepthalates, polymethylmethacrylates, ethylene ethylacrylates,polyethyl hexylacrylates, plasticized ethylene vinylacetates, polyvinylacetates, ethylene vinyl acetates, ethylene vinyl alcohols, polyvinylalcohols, cross-linked polyvinyl alcohols, cross-linked polyvinylbutyrates, polyvinylbutyrates, polybutylmethacrylates, polyvinylchlorides, ethylene vinylchloride copolymers, silicones, polysiloxanes,substituted polysiloxanes, polyethylene oxides, polyethylene glycols(PEG), polybutylene terepthalate-co-PEG, PCL-co-PEG, PLA-co-PEG,polyvinyl acetals, polyvinyl acetates, polyamides, polyvinylpyrrolidones, polyacrylamides, polyvinyl esters, copolymers thereof,polymer derivatives thereof, and/or combinations thereof.

Implantable devices 180 may include endoprostheses, drug deliverystents, drug delivery catheters, stent-grafts, grafts, drug deliveryballoons, guidewires, orthopedic implants, PFO closure devices,pacemaker leads, dental implants, fixation screws, indwelling catheters,implantable filters, ocular implants, pharmacotherapeutic implants,blood-contacting components of extracorporeal devices, staples, filters,needles, tubes, coils, wires, clips, screws, sensors, plates, conduits,portions thereof, combinations thereof, and/or other implantabledevices.

In one embodiment, the implantable device may include an endoprosthesisfor controlling the release of an active agent therefrom. Such anendoprosthesis can include the following: a supporting metal structureconfigured and dimensioned to be used within a body of a human; a porousbody disposed on and at least partially covering the supporting metalstructure, the porous body including a first biocompatible materialhaving a plurality of pores; a therapeutically effective amount of anactive agent disposed within the pores, the therapeutically effectiveamount of the active agent being capable of treating and/or preventing adisease; an elution rate controlling matrix disposed within the porousbody so as to contain the active agent within the pores, the matrixmaterial including a polymeric biocompatible material that at leastpartially controls an elution rate of the active agent from the pores;and the pores each having a dimension that is configured to at leastpartially determine the elution rate.

In one embodiment, the implantable device may include a stent forcontrolling the release of an active agent therefrom. Such a stent caninclude the following: a superelastic metal structure configured anddimensioned as a stent to be used within a lumen of an animal; a porousbody disposed on and at least partially covering the superelastic metalstructure, the porous body including a first biocompatible materialhaving a plurality of pores; a therapeutically effective amount of anactive agent disposed within at least a portion of the pores, thetherapeutically effective amount of the active agent being capable oftreating and/or preventing a disease; and an elution rate controllingmatrix disposed on at least one surface of the porous body so as tocontain the active agent within at least a portion of the pores, thematrix material including a second biocompatible material that controlsan elution rate of the active agent from the pores. Optionally, theporous body is integrated with the supporting structure.

In another embodiment, the implantable device may include anendoprosthesis for controlling the release of an active agent therefrom.Such an endoprosthesis may include a supporting metal structureconfigured and dimensioned to be used within a body of a human, acoating body disposed on and at least partially covering the supportingmetal structure, the coating body including a first biocompatiblepolymeric material having a largely homogeneous structure, atherapeutically effective amount of an active agent combined with thebiocompatible polymeric material to make a largely homogeneouscomposition, the therapeutically effective amount of the active agentbeing capable of treating and/or preventing a disease, and thebiocompatible polymeric material being either a durable or abiodegradable polymer.

In a further embodiment, the implantable device may include a lumenfilter such as a vena cava filter. The lumen filter may include astructure configured and dimensioned as a filter to be used within alumen of an animal; a porous body disposed on and at least partiallycovering the structure, the porous body may include a firstbiocompatible material having a plurality of pores; a therapeuticallyeffective amount of an active agent disposed within at least a portionof the pores, the therapeutically effective amount of the active agentbeing capable of treating and/or preventing a disease; and an elutionrate controlling matrix disposed on at least one surface of the porousbody so as to contain the active agent within at least a portion of thepores, the matrix material may include a second biocompatible materialthat controls an elution rate of the active agent from the pores.Optionally, the porous body is integrated with the supporting structure.

FIG. 2 illustrates a schematic representation of an embodiment of asystem 200 for rotating and coating an implantable device 280, inaccordance with the present invention. The system 200 of this embodimentmay be functionally similar to that of the system 100 previouslydescribed above and shown in FIG. 1 in most respects, wherein certainfeatures will not be described in relation to this embodiment whereinthose components may function in the manner as described above and arehereby incorporated into this alternative embodiment described below.Like structures and/or components are given like reference numerals.

The system 200 may include a material delivery apparatus 202 that mayapply an application material 270 to an implantable device 280. Thedelivery or loading of the application material 270 to the implantabledevice 280 can be varied through use of a controller 203, the materialdelivery apparatus 202, a positioning assembly 204, and/or othercomponents. For instance, the controller 203 can be programmed with thestructural configuration of the implantable device 280 and controldelivery or loading the application material 270 through controlling theoperation of the material delivery apparatus 202, the positioningassembly 204, and/or other components.

The positioning assembly 204 can include a driver assembly 206 thatcreates relative movement between the implantable device 280 and thematerial delivery apparatus 202. The positioning assembly 204 can alsoinclude a rotation assembly 205 that creates rotational movement. Therotation assembly 205 may include a rotation member 210 configured to,at least in part, support and/or rotate the implantable device 280.

As mentioned above, the controller 203 in communication with the driverassembly 206 can define a dispensing path of relative movement betweenthe material delivery apparatus 202 and the rotation assembly 205. Thecontroller 203 can also communicate with the material delivery apparatus202 for selectively dispensing application material 270 in a selectedformat along the dispensing path onto a selected portion of theimplantable device 280 supported and/or rotated by the rotation member210. In one configuration, the rotation assembly 205 supporting and/orrotating the implantable device 280 is longitudinally moveable while thematerial delivery apparatus 202 remains stationary during dispensing ofapplication material 270. However, in another aspect of the inventionthe rotation assembly 205 supporting and/or rotating the implantabledevice 280 may remain longitudinally stationary (although may stillrotate) while the material delivery apparatus 202 moves along thedispensing path. Alternatively, both the rotation assembly 205 andmaterial delivery apparatus 202 are longitudinally moveable.

The rotation assembly 205 may be configured to rotate the implantabledevice 280 at a relative speed. In some embodiments, the relative speedmay be between about 30 revolutions per minute and about 3000revolutions per minute. In one embodiment, the relative speed may bemore than about 120 revolutions per minute.

In some embodiments, relative speeds above 3000 revolutions per minutemay reduce coating efficiency. In further embodiments, relative speedsbelow 120 rpm may be insufficient to reduce the size of at least aportion of the droplets. The relative speed may increase with respect tothe dimensions of the implantable device 280. For instance, the relativespeed may be directly proportional to a dimension (i.e. a diameter,width, other dimension, or combinations of the same) of the implantabledevice 280.

Rotating the implantable device 280 may include rotating about an axis,generally about an axis (i.e. the axis may move throughout therotation), rotating about a path, revolving about the rotation member210, and/or other types of rotation. Rotating the implantable device 280may also include wobbling, precession, and/or other non-uniform types ofrotation.

In another configuration, the system 200 can include a detector orsensor to detect when the material delivery apparatus 202 is alignedwith the selected portions of the implantable device 280. Such adetector or sensor can be an optical detector, e.g., linear arraydetector or infrared detector, ultrasound probe, temperature probe,camera, capacitance meter, electrometer, hall-effect probe, and thelike, or any other sensor or detector for detection.

In a further configuration, the system 200 can include a focusingassembly to aid delivery or loading application material 270 throughvarying or changing the spray pattern of the application material 270.The focusing assembly may include at least one focusing jet, an annularjet, and/or other focusing assembly components.

With continued reference to FIG. 2, the positioning assembly 204 canfurther include a longitudinal driver 218. The rotation assembly 205 canlikewise further include a rotating driver 216. The rotation member 210may be rotated by the rotation driver 216, which can include a motor.For instance, the rotating driver 216 can be activated to produce avelocity on the implantable device 280 via the rotation member 210during application material delivery. In some embodiments, the velocitymay be a constant angular velocity. Similarly, the longitudinal driver218 can control advancement of the implantable device 280 longitudinallypast the material delivery apparatus 202. Again, the longitudinal driver218 can include a motor.

Through the system 200, application material 270 can be loaded ordelivered to an implantable device 280 in a controlled manner. Thesystem 200 may enable and facilitate relative movement between thematerial application apparatus 202 and the implantable device 280 todefine a dispensing path along which the application material 270 can beselectively dispensed. The positioning assembly 204 and/or rotationassembly 205 may aid the delivery or loading of the application material270 through varying or changing the spray pattern of the applicationmaterial 270. Hence, the application material 270 may be selectivelydispensed from the material application apparatus 210 to a predeterminedportion of the implantable device 280 along the dispensing path.

The dispensing path can include, for example, a sequential series oflinear parallel passes that traverse back and forth along one axis ofthe implantable device 280. The relative motion can be continued in alinear manner between forward and backward or right to left and left toright or upward and downward, depending on the frame of reference. Atraversal or a pass can be completed when the relative motion reversesdirection. That is, relative motion may continue up to a point on thedevice or past the implantable device, and then may decelerate, stop,reverse direction, and/or accelerate to a constant velocity. In someembodiments, no deceleration is necessary (i.e. if the motion stopsimmediately). After each pass, the system 200 may adjust the position ofthe material delivery apparatus 202 and/or implantable device 280. Forexample, the relative position of the material delivery apparatus 202and/or the implantable device 280 may be changed or incremented to limitthe possibility of application overlap, although a certain degree ofoverlap may be permitted.

Alternatively, the dispensing path created by the relative motion of thematerial delivery apparatus 202 and/or the implantable device 280 caninclude a single continuous helix that wraps continuously around thebody of the implantable device 280 and along the length of theimplantable device 280. Alternatively, the dispensing path can include anon-continuous helix.

FIG. 3 illustrates an embodiment of an implantable device 380, inaccordance with the present invention. The implantable device 380, inthe present embodiment, is a stent. The implantable device 380 may begenerally annular and oriented about a longitudinal axis 381. Theimplantable device 380 may include various struts 382.

FIG. 4 illustrates a cross-sectional view of an embodiment of animplantable device 480 and a rotation member 410, in accordance with thepresent invention. The implantable device 480 and rotation member 410 ofthis embodiment may be functionally similar to that of the implantabledevices 180, 280, 380 and rotation members 210, 410 previously describedabove and shown in FIGS. 1-3 in most respects, wherein certain featureswill not be described in relation to this embodiment wherein thosecomponents may function in the manner as described above and are herebyincorporated into this alternative embodiment described below. Likestructures and/or components are given like reference numerals. Forexample, in some embodiments, the implantable device 480 may be a stent,such as the implantable device 380 shown in FIG. 3.

The cross-section of the implantable device 480 may be generally annularand may include a longitudinal axis 481, an inside diameter 484, and aninner surface 486 (i.e. ablumenal surface). The cross section of therotation member 410 may include a longitudinal axis 411, an outsidediameter 412, and an outer surface 413. The outer surface 413 of therotation member 410 may contact, at least partially, the inner surface486 of the implantable device 480.

The inside diameter 484 of the implantable device 480, in the presentembodiment, may range from about 0.05 mm to about 2.0 mm. In otherembodiments, the inside diameter 484 may be about 1.0 mm. The outsidediameter 412 of the rotation member 410, in the present embodiment, mayrange from about 0.003 mm and about 1.7 mm. In other embodiments, theoutside diameter 412 of the rotation member 410 may range from about 0.5mm to about 0.7 mm. In further embodiments, other ranges of insidediameter 484 and outside diameter 412 may be used. Ratios of insidediameter 484 and outside diameter 412 may be used. For example, theoutside diameter 412 of the rotation member 410 may be more than about5% and less than about 100% of the outside diameter 412 of the rotationmember 410. In another example, the outside diameter 412 of the rotationmember 410 may be more than about 50% and less than about 70% of theinside diameter 484 of the implantable device 480. In one embodiment,the rotation member 410 may be a needle.

In the present embodiment, the longitudinal axis 411 of the rotationmember 410 and the longitudinal axis 481 of the implantable device 480are offset by a desired dimension 497. The desired dimension 497 may beselected to increase the “footprint” the outer surface 413 of therotation member 410 has on the inner surface 486 of the implantabledevice 480. The “footprint” of the outer surface 413 may affect theamount of friction generated between the rotation member 410 and theimplantable device 480.

In some embodiments, the desired dimension 497 may be between about 0.02mm and about 1.97 mm. In further embodiments, the desired dimension 497may be between about 0.3 mm and about 0.5 mm. In still furtherembodiments, the desired dimension may be between about 5% and about500% of the outside diameter 412 of the rotation member 410.

In one embodiment, less than the entire outer surface 413 of therotation member 410 may be in general contact with less than the entireinner surface 486 of the implantable device 480. For example, as shownin FIG. 4, only a portion of the outer surface 413 of the rotationmember 410 is in contact with the inner surface 486 of the implantabledevice 480. In addition, the inner surface 486 and/or the outer surface413 may be non-uniform. For example, the implantable device 380, shownin FIG. 3, may have a non-uniform inner surface. Furthermore, the innersurface 486 and/or outer surface 413 may have varying surface qualitiesand/or other characteristics that may facilitate rotation of theimplantable device 480.

The use of a rotation member 410 may allow rotation of the implantabledevice 480 without using an interference fit, clamps, and/or othermechanisms for holding the implantable device 480. For example, therotation member 410 may be rotationally associated with a rotationmechanism, such as the rotation mechanism 216 described in connectionwith FIG. 2. The implantable device 480 may be rotated at a relativespeed (or velocity) by its interaction with the rotation member 410. Forexample, as a rotational force is applied to the rotation member 410,the outer surface 413 of the rotation member 410 may rotate at aspecified rotation speed. The rotation of the outer surface 413 mayapply at least a partial frictional force to at least a portion of theinner surface 486 of the implantable device 480.

The frictional force between the outer surface 410 of the rotationmember 410 and the inner surface 486 of the implantable device 480 maycause the implantable device 480 to rotate at a speed corresponding tothe specified rotation speed of the rotation member 410. Thecorrespondence in rotation speeds may be proportional, in someembodiments. The frictional force between the outer surface 410 of therotation member 410 and the inner surface 486 of the implantable device480 may result from a buildup of kinetic energy between at least aportion of the outer surface 413, at least a portion of the innersurface 486, and/or a fluid between at least a portion of the outersurface 413 and at least a portion of the inner surface 486 when therotation member 410 is rotated relative to the implantable device 480.

FIG. 5 illustrates a cutaway perspective view of an embodiment of animplantable device having struts 582 a, 582 b and various droplets 571of an application material, in accordance with the present invention.The struts 582 a, 582 b of the implantable device of this embodiment maybe functionally similar to the struts 382 of the implantable device 380previously described above and shown in FIG. 3 in most respects, whereincertain features will not be described in relation to this embodimentwherein those components may function in the manner as described aboveand are hereby incorporated into this alternative embodiment describedbelow. Like structures and/or components are given like referencenumerals.

The struts 582 a, 582 b may include an inner surface (not shown), anouter surface 585, edges 583, side surfaces 587, and/or other edgesand/or surfaces. The struts 582 a, 582 b may be parallel to each otherand/or may be oriented in another manner. The struts 582 a, 582 b mayhave a square cross-section, a rectangular cross-section, a roundedcross-section, and/or other cross-sectional shapes. In one example, thestruts 582 a, 582 b may be shaped similarly to the struts 382 shown inFIG. 3. The droplets 571 of application material may contact these edgesand/or surfaces.

The struts 582 a, 582 b may move as indicated in FIG. 5. In the presentembodiment, the struts 582 a, 582 b may rotate, i.e. about an axis (notshown). The droplets 571 of application material may also be moving asindicated. In the present embodiment, the droplets 571 may be applied ina direction generally perpendicular to a longitudinal axis (not shown)of the implantable device.

The droplets 571 of the application material may impinge or otherwisecontact the struts 582 a, 582 b. In the present embodiment, some of thedroplets 571 may be sheared or otherwise reduced into smaller droplets571 a, 571 a′, 571 a″. For example, a droplet 571 may contact an edge583 of the strut 582 b. The droplet 571 may split into smaller droplets571 a, 571 a′, 571 a″. In this example, droplet 571 a′ may contact andcoat a portion of the side surface 587, outer surface 586, and edge 583.

Droplets may also be sheared or otherwise reduced without contacting anedge 583 of a strut 582 a, 582 b. A strut having a rounded cross-sectionmay nevertheless shear and/or otherwise reduce a droplet 571 based onthe speed of the strut and/or the droplet 571. Centripetal and/orcentrifugal forces may also contribute to the shearing and/or reductionof droplets 571.

A portion of the droplets 571 may be deflected from a first portion ofthe implantable device toward a second portion of the implantabledevice. For example, droplet 571 a″ is shown as being deflected fromstud 582 b toward (and onto) stud 582 a. Deflection of a portion of thedroplets from a first portion of the implantable device toward a secondportion of the implantable device may be accomplished by rotating theimplantable device at a relative speed.

In some embodiments, the relative speed may be sufficient to reducebuildup of the application material. For example, at a relative speedthat is not sufficient to reduce buildup of the application material,droplet 571 a″ may remain on the outer surface 585 of the strut 582 b.As these droplets 571 a″ build up on the strut 572 b, defects, such aswebbing and/or other defects, may form. By using a sufficient relativespeed, these droplets 571 a″ may not accumulate, but rather may betransferred to other surfaces of the implantable device (i.e. the sidesurface 587 of strut 582 a).

Some droplets 571 b may not be sheared or otherwise reduced into smallerdroplets. Rather, these droplets 571 b may coat a portion of the strut582 a, 582 b. Some of these droplets 571 b may coat a portion of asingle surface, such as the outer surface 585 and/or side surface 587.Other of these droplets 571 b may coat portions of multiple surfaces.

Although the inner surface and one side surface of the struts 582 a, 582b are not shown, droplets 571 may coat a portion of these surfaces. Forexample, if the implantable device is generally annular, droplets 571,i.e. either sheared droplets 571 a, 571 a′, 571 a″ and/or unsheareddroplets 571 b, may coat a portion of the inner surface (i.e. ablumenalside). In another example, a droplet 571, i.e. either sheared droplets571 a, 571 a′, 571 a″ and/or unsheared droplets 571 b, may impinge on aportion of the side surface 587 of the strut 582 a, 582 b near the innersurface and coat a portion of the inner surface and/or side surface 587.In some embodiments, the relative speed may be sufficient to coat aportion of the inner surface with the application material withoutincreasing a flow rate of the application material.

FIG. 6 illustrates an embodiment of a method 600 for rotating andcoating an implantable device, in accordance with the present invention.In the present embodiment, the method 600 may be used in conjunctionwith the systems 100, 200 and components described in connection withFIGS. 1-5, and/or any other system or components for rotating andcoating an implantable device described herein. For example, therotation system 105 may be used to rotate the implantable device 180.

An implantable device may be positioned relative to a material deliveryapparatus, as represented by block 602. Positioning an implantabledevice relative to a material delivery apparatus may include positioningthe implantable device in a desired location and/or in a desiredorientation. For example, a stent may be positioned between about 6 mmand about 30 mm from a nozzle of a material delivery apparatus and/ormay be oriented perpendicular to the application material being applied.

In some embodiments, before and/or during the application of theapplication material to the implantable device, an electric charge maybe applied to the material delivery apparatus and/or the implantabledevice. For example, the system component may be charged before applyingthe application material, but not during the application of theapplication material. In this example, the system component maynevertheless be charged by virtue of, for example, retaining the charge.In further embodiments, before applying the application material to theimplantable device, the material delivery apparatus and/or theimplantable device may be grounded.

The implantable device may be rotated at a relative speed, asrepresented by block 604. The implantable device may be rotated at arelative speed between about 30 revolutions per minute and about 3000revolutions per minute. Rotating the implantable device at a relativespeed may include rotating a rotation member to cause the implantabledevice to rotate at the relative speed, rotating the implantable devicevia a holder and/or other device, and/or other methods of rotating theimplantable device at a relative speed.

A spray pattern of an application material may be produced, asrepresented by block 606. Producing a spray pattern of an applicationmaterial may include directing and/or focusing the spray pattern using,for example, focusing jets.

Rotating the implantable device may include rotating the implantabledevice at a relative speed sufficient to reduce the size of and/or toincrease the spatial resolution of a portion of the droplets of thespray pattern. For example, when the implantable device is rotated at asufficient relative speed, the struts and/or other portions of theimplantable device may shear or otherwise reduce the size of a portionof the droplets of the spray pattern. In another example, when theimplantable device is rotated at a sufficient relative speed, the numberof droplets in a volume may increase.

FIG. 7 illustrates a block diagram of a still further embodiment of asystem 700 for rotating and coating an implantable device 780, inaccordance with the present invention. The system 700 of this stillfurther embodiment may be functionally similar to that of the systems100, 200 and components previously described above and shown in FIGS.1-5 in many respects, wherein certain features will not be described inrelation to this still further embodiment wherein those components mayfunction in the manner as described above and are hereby incorporatedinto this alternative embodiment described below.

The system 700 includes a material delivery apparatus 702 that may applyan application material 770 to an implantable device 780 and may includea rotation assembly 705. The material delivery apparatus 702, in thepresent embodiment, may be an ultrasonic material delivery apparatusthat may include an ultrasonic power generator 722, a transducer 724, ahousing 732, a nozzle body 734, a nozzle holder 736, an ultrasonictransducer horn 738, a pressure source 740, an application materialreservoir 750, and/or an application material delivery apparatus 760.

The system 700, in the present embodiment, may include an ultrasonicgenerator. The ultrasonic generator may include an ultrasonic powergenerator 722 and at least one transducer 724. The ultrasonic powergenerator 722 may generate high frequency electrical energy. Highfrequency electrical energy may be generated in the range, for example,from about 20 kHz to about 120 kHz. The frequency may be determinedbased on the characteristics of the nozzle body 734 and/or ultrasonichorn 738.

The ultrasonic power generator 722 may be in electrical communicationwith at least one transducer 724. The at least one transducer 724 mayconvert the electrical energy generated by the ultrasonic powergenerator 722 into mechanical (i.e. vibration) energy. The transducers724 may include piezoelectric transducers to facilitate in atomizing theapplication material 770.

The housing 732 may house the nozzle body 734. The housing 732 may beconnected to the nozzle holder 736. The nozzle holder 736 may be used toposition the material delivery apparatus 702 with respect to theimplantable device 780.

In the present embodiment, the material delivery apparatus 702 mayinclude both an application material delivery apparatus 760 and a nozzlebody 734 and ultrasonic horn 738. In other embodiments, otherconfigurations may be used. For example, the nozzle body 734 andultrasonic horn 738 may be in fluid communication with the applicationmaterial reservoir 750 and a pressure source 740.

The nozzle body 734 and/or the ultrasonic horn 738, in the presentembodiment, may be in fluid communication with a pressure source 740.The pressure source 740 may include an air pressure source. The pressuresource 740 may generate a pressurized fluid that may be shaped and/ordirected by the nozzle body 734 and/or the ultrasonic horn 738. Thepressure source 740, in the present embodiment, may generate alow-pressure air stream. In one embodiment, ultrasonic horn 738 may behollow with the gas from pressure source 740 passing through it.

The application material delivery apparatus 760 may be connected to anapplication material reservoir 750. The application material reservoir750 may include a pump, pressurized reservoir, gravity system, and/orother delivery mechanism to direct the application material 770 to theapplication material delivery apparatus 760. The application materialdelivery apparatus 760 may include a hypotube. The application materialdelivery apparatus 760 may deliver the application material 770 to theultrasonic horn 738 to facilitate atomization of the applicationmaterial 770. In some embodiments, the application material deliveryapparatus 760 may have an electric charge and/or be grounded. In furtherembodiments, the application material delivery apparatus 760 may beselectively electrically isolated from the ultrasonic power generator722.

System components may have an electric charge or be grounded. Thequantity of electric charge of the charged system components may begenerally selected based on a desired application material 770trajectory. Furthermore, a portion of the system 700 may have a positiveor negative charge and/or the system 700 may include a positively ornegatively charged conductive member. For example, the components of thesystem 700 may have a positive or negative charge and/or the system 700may include a positively or negatively charged conductive member asdisclosed in U.S. Provisional 61/015,126, filed Dec. 19, 2007, andentitled “Methods for Applying an Application Material to an ImplantableDevice”, the disclosure of which is hereby incorporated by reference inits entirety.

The implantable device 780 may be rotated and/or held using the rotationassembly 705. The relative speed of the rotation of the implantabledevice 780 may be determined based on various characteristics of thesystem 700. For example, the flow rate of the application material 770,the size of the droplets generated by the system 700, the trajectory ofthe spray pattern, and/or other system characteristics may beconsidered.

The invention is susceptible to various modifications and alternativemeans, and specific examples thereof have been shown by way of examplein the drawings and are herein described in detail. It should beunderstood, however, that the invention is not to be limited to theparticular devices or methods disclosed, but to the contrary, theinvention is to cover all modifications, equivalents, and alternativesfalling within the spirit and scope of the claims.

1. A method for applying a coating to an implantable device, comprising:positioning an implantable device relative to a material deliveryapparatus; rotating the implantable device at a relative speed of morethat about 120 revolutions per minute; and producing a spray pattern ofan application material using the material delivery apparatus.
 2. Themethod of claim 1, wherein the relative speed is between about 200revolutions per minute and about 3000 revolutions per minute.
 3. Themethod of claim 2, wherein a distance between the implantable device andthe material delivery apparatus is between about 1 mm and about 50 mm.4. The method of claim 1, wherein the implantable device is a stent. 5.A method for applying a coating to an implantable device, comprising:positioning an implantable device relative to a material deliveryapparatus; producing a spray pattern of an application material usingthe material delivery apparatus; and rotating the implantable device ata relative speed sufficient to reduce the size of a portion of dropletsof the spray pattern.
 6. The method of claim 5, wherein the relativespeed is generally sufficient to deflect a portion of the droplets ofthe spray pattern from a first portion of the implantable device towarda second portion of the implantable device.
 7. The method of claim 5,wherein the relative speed is generally sufficient to coat at least aportion of an internal surface with application material withoutincreasing a flow rate of the application material.
 8. The method ofclaim 5, wherein the relative speed is generally sufficient to reducebuildup of the application material.
 9. A system for rotating animplantable device, the system comprising: an implantable device havinga first longitudinal axis and an inside diameter; and a rotation systemconfigured to rotate said implantable device including a rotation memberhaving a second longitudinal axis and an outside diameter, said rotationmember being rotationally associated with a rotation mechanism, and whensaid first longitudinal axis and said second longitudinal axis aregenerally parallel said first longitudinal axis and said secondlongitudinal axis are offset a desired dimension.
 10. The system ofclaim 9, wherein said desired dimension is between about 0.02 mm andabout 1.97 mm.
 11. The system of claim 9, wherein said desired dimensionis between about 0.3 mm and about 0.5 mm.
 12. The system of claim 9,wherein said desired dimension is between about 5% and about 5000% ofsaid outside diameter of said rotation member.
 13. A system for rotatingan implantable device, the system comprising: an implantable devicehaving an inside diameter; a rotation system configured to rotate saidimplantable device including a rotation member having an outsidediameter, said rotation member being rotationally associated with arotation mechanism, and said outside diameter of said rotation memberbeing smaller than said inside diameter of said implantable device. 14.The system of claim 13, wherein said inside diameter of said implantabledevice is between about 0.05 mm and about 2.0 mm.
 15. The system ofclaim 13, wherein said outside diameter of said rotation member isbetween about 0.03 mm and about 1.7 mm.
 16. The system of claim 13,wherein said outside diameter of said rotation member is between about0.5 mm and about 0.7 mm and said inside diameter of said implantabledevice is about 1.0 mm.
 17. The system of claim 13, wherein said outsidediameter of said rotation member is more than about 5% and less thanabout 100% of said inside diameter of said implantable device.
 18. Thesystem of claim 13, wherein said outside diameter of said rotationmember is more than about 50% and less than about 70% of said insidediameter of said implantable device.
 19. A method for rotating animplantable device, the method comprising: positioning a generallyannular implantable device having an inner surface relative to arotation member having an outer surface such that less than the entireinner surface of the implantable device and less than the entire outersurface of the rotation member are in general contact with each other;and applying a rotational force to the rotation member, such that therotation member begins to rotate at a specified rotation speed causingat least a portion of the outer surface of the rotation member to applya frictional force to at least a portion of the inner surface of theimplantable device.
 20. The method of claim 19, wherein the frictionalforce between the rotation member and the implantable device causes theimplantable device to rotate at a speed corresponding to the specifiedrotation speed of the rotation member.
 21. The method of claim 19,wherein the frictional force between at least a portion of the outersurface of the rotation member and at least a portion of the innersurface of the implantable device is due to the build up of kineticenergy between at least a portion of the outer surface of the rotationmember and at least a portion of the inner surface of the implantabledevice when the rotation member is rotated relative to the implantabledevice.
 22. The method of claim 19, wherein the frictional force betweenat least a portion of the outer surface of the rotation member and atleast a portion of the inner surface of the implantable device is due tothe build up of kinetic energy between at least a portion of the outersurface of the rotation member, at least a portion of the inner surfaceof the implantable device, and a fluid between at least a portion of theouter surface of the rotation member and at least a portion of the innersurface of the implantable device when the rotation member is rotatedrelative to the implantable device.